introduction to pse-lab · simulation of chemical processes 11 • steady-state simulation of...

Introduction to PSE-Lab

© Introduction to PSE-Lab

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Politecnico di Milano

Politecnico di Milano (POLIMI) was founded

on November, 29th 1863,

…more than 150 years ago…

The logo originates from Raffaello’s fresco The

School of Athens, whose cartoon is at the

Ambrosiana Gallery, Milano

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Lab Campus at POLIMI

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84% of graduates in Italy



Faculty & Students as of 2010

Design

Architecture

Engineering

Professors & Researchers Students

329 10.187


101 4.630


888 23.216

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Professor Giulio Natta received the

Nobel Prize for Chemistry in 1963

for the discovery of polypropylene

The Nobel prize 5


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PSE-Lab @ POLIMI

Politecnico di Milano

Engineering School

• Chemistry, Materials and Chemical Engineering Department

– PSE-Lab

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PSE-Lab

The Process Systems Engineering Laboratory

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8 Main research activities

• Introduction

• Design and Simulation

• Dynamics and Control of chemical processes

• Process monitoring and soft sensors

• Data reconciliation

• On-line optimization

• Scheduling, Planning, Supply Chain Management

• Dynamic Accident Simulation

• Reconstruction of Accident Dynamics

• OTS

• Performance assessment

• Decision support systems


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9 Equipment Design

• Equipment Design and Process Design

• Both conventional and unconventional process

units can be designed for optimal operation.

Starting from basic unit operations up to innovative

and peculiar equipment the research group can provide

solutions in as different fields as energy, separation, reaction, and utilities.

• Examples of some delivered design projects: distillation columns, reactors, heat

exchangers, furnaces, waste heat boilers, dust removal systems, Venturi scrubbers,

absorbers, strippers, moving bed reactors, and fluidized bed driers.

• Software: PRO/II, UniSim, HYSYS, Aspen Plus, and other in-house tools


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10 Dynamic Conceptual Design

• Conceptual design of chemical processes.

• Optimal process layout as a compromise between

fixed capital investment and working capital.

Conventional approach based on economic potential

and advanced approach based on superstructures.

• Dynamic conceptual design as a function of price and cost fluctuations within the

short, medium and long time horizons.

• Role played by market uncertainty on the revamping and retrofitting of existing

plant.

• Applied studies focused on the dynamic allocation of resources for energy

production and heat recovery systems.

• Synthesis of Heat Exchange Networks (either pinch technology or superstructures)


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11 Simulation of chemical processes

• Steady-state simulation of complex units and industrial processes

• Steady-state simulation of nominal operating conditions

• Quantification of the lower and upper limits for an efficient use of the equipment

respect to the nominal operating conditions

• The Process Systems Engineering group has a long tradition in the deployment of

simulation programs for chemical processes. A few examples deal with the

simulation of distillation columns, reacting systems, chemical and petrochemical

processes, and water treatment units.


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12 Dynamic Simulation

• Plant design has become increasingly complex, integrated and interactive.

• Heat integration, process recycles and minimum hold-ups are typical design features.

• These design issues optimize steady state operation. However, they present

particular challenges to plant control and operation engineers.


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• Dynamic Simulation for:

• Advanced Process Control applications

• a priori inspection of control loop alternatives

• effectiveness of start-up and shutdown procedures

• The PSE group has a long tradition on dynamic simulation. A few examples

are: reactor and heat exchanger networks, distillation columns, chemical and

petrochemical processes.

• Software: Dynsim, Aspen HYSYS, UNISIM, and in-house tools

Dynamic Simulation


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14 Dynamic process and accident simulation

Process Dynamic Simulator

Dynamic Accident Simulator

Flow rate

L/V fractions

Temperature

Heat radiation

Toxic concentration

Overpressure

AXIM™ is a dynamic accident simulator that can be either

linked to a process dynamic simulator by means of OPC

protocol, DLL, OBJ or work as a standalone package


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AXIM™

Flow rate L/V fractions Temperature

Heat radiation Toxic concentration

Overpressure

Dynamic process and accident simulation


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16 Process monitoring

• Process monitoring

• Data acquisition

• Process identification: ARX, ARMAX, NARX, ANN

• Soft sensors for:

• Inferentiation of unmeasurable quantities

• Instrumentation redundancy

• Replacement of off-line measures

• Replacement of measuring devices with

high time delays

(e.g. gas-chromatographs)


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17 Data reconciliation

Process Model IN OUT

Data Reconciliation

DCS

Supervision system

Process

Data acquisition

Statistical analysis


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18 On-line process optimization

Identification of the optimal set points subject to the dynamically changing process conditions

Advanced Process Control

Allocation of raw materials

Minimization of utilities and energy requirements

Scheduling and Planning of industrial production

Supply chain management of crude-oil. From reservoir to final products distribution


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19 Process supervision

Control Performance & Business Performance

Market info

Supply info


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20 Supply chain management


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STORAGE TANKS CRUDE OIL CARRIERS

BLENDING VESSELS

PRODUCTION SITES with

distinct processes

FINAL PRODUCT TANKS FINAL USERS

ARBOUR WITH N DOCKS

Supply chain management


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Operator Training Simulation 22/18


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23 Operator Training Simulation

Conventional Operator Training Simulation

From the design realm to the on-line process control domain

The main reason for OTS is training from scratch the operators

Training of specialized manpower

Usually focused on control-room operator training

Important for simulating both rare and unconventional events:

off-spec conditions

grade changes

start-up and shutdown procedures

• planned shutdown

• emergency shutdown


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24 Operator Training Simulation

Need for field operator training

conventional OTS are not so good at training field operators

Conventional OTSs are not capable of simulating accidental events

Need for a dynamic process simulation of industrial accidental events

Coupling of Dynamic Process and Accident Simulation


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25 Process and Accident OTS

Benefits of coupling Process and Accident dynamic simulators:

improvement of the operator knowledge

analysis of very rare accidental events

understanding of process behavior under emergency

quantitative evaluation of accidental outcomes

slow-motion and fast-motion analysis of accidental events

recording and playback of operator actions

performance evaluation of operator actions

Outcomes

Quantification and visualization of iso-radiative flux curves

Quantification and visualization of iso-concentration curves

Evaluation of the toxic dose absorbed in a point of the plant

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introduction to pse-lab · simulation of chemical processes 11 • steady-state simulation of...

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